The metal casting process had already existed even in the early days. Various shapes of metal are being created after a liquid metal is poured into a mold. Once it has cooled off, the metal casting will be extracted from its mold. There is no doubt that metal casting is one of the most influential manufacturing processes throughout history.
It is commonly used for creating different types of metal objects which are relevant in our daily lives. Metal casting products include automotive parts, plumbing parts, electrical parts, and others. Additionally, the metal casting industry is recycling metals which can help in lessening the number of scrap metals that can end up in landfills.
How is Metal Casting Processed?
The first step in the metal casting process is patternmaking. A pattern will show what the exterior part of the casting will be. Commonly, patterns are created from metal, wood, or plastic. Patternmaking should be done accurately to make sure that it can fit precisely.
For hollow castings, you need to create a core that is either made of sand or metal. This will create the internal shape of the casting. Cores must be sturdy yet can be folded so it can be easily removed when the casting is done.
The History of Metal Casting
It was believed that metal casting has started in 3200 BCE in Mesopotamia wherein they were able to create a copper frog. However, it was in 700 BCE when the first cast iron was produced in China. Additionally, the sand casting was first introduced in China in 645 BCE.
The crucible technique was first introduced in India and central Asia. In 800 CE, it was introduced in northern Europe as a means for creating Viking swords. It took a while before it made a reappearance in 1750. During this time, Benjamin Huntsman used an enclosed crucible in heating small bits of carbon steel. Huntsman was able to reach a high temperature which melted the steel.
Over the years, metal casting has evolved. The process became more accurate and automated, making it easier to produce large volumes of casting products.
The next step is to create a mold throughout the pattern by using molding sand or green sand. The mold will be placed inside a frame. Molding sand or green sand will be filled up into the frame surrounding the pattern. On the other hand, you could also create a two-piece mold that can be used multiple times for casting similar parts.
Once your mold is ready, you can now pour your liquid metal and wait until it hardens. By the time that it has already solidified, the sand will be removed from the casting. The removed sand can be reused again for creating more castings.
Finally, once the metal casting has been removed from the mold, it must be cleaned up from any molding material.
Modern Day Metal Castings
Nowadays, almost all of the mechanical devices are using metal parts produced from the metal casting process. The difference between modern-day metal casting products and those that were produced during the early times is the accuracy and tolerance which we can easily achieve by using a computerized design process. Also, there are now highly advanced methods for creating accurate cores and molds.
Throughout the years, there were different types of raw materials being developed to create different variations of metal. Some of these metal casting products are used in engines, hence, it should be able to withstand extreme heat and cold.
Pipes that are made of iron casting must be able to resist corrosion and high pressures. Some metal castings need to be durable yet lightweight. The metal cast can also be designed to permit tolerance between expansion and reduction.
SEI Castings is a leading metal caster that can produce products made of aluminum and zinc. Whether you need small or large quantities, SEI Castings is the best choice for high-quality die castings. We can also help you reduce the manufacturing cost of your product. To get more information about our products, you can contact us at 408-662-4887 or take a look at our website.
The pattern should be a bit larger since the mold is also slightly larger. This can offset the contraction of molten metal once it has cooled down. The product from a sand casting usually has a rough surface.